Method of making prepared building products



May 16, 1.933. 1:. ROBINSON METHOD OF MAKING PREBARED BUILDING PRODUCTSOriginal Filed,June -19, 1928 2 Sheets-Sheet 1 INVEgTOR ATTORNEYS- Z;lad

May 16, 1933. 1'. ROBINSON 1,909,313

METHOD OF MAKING PREPARED BUILDING PRODUCTS Original Filed June 19, 19282 Sheets-Sheet 2 ATTORNEYS Patented May 16, 1933 UNITED STATES PATENTOFFICE THOMAS ROBINSON, OF NEW YORK, N. Y., ASSIGNOR TO LANCASTERASPHALT, INQ,

OF NEW YORK, N. Y., A CORPORATION OF DELAWARE METHOD OF MAKING PREPAREDBUILDING PRODUCTS Original application filed June 19, 1928, Serial No.286,502. Divided and this application filed July 16,

1929. Serial This invention relates to building products capable ofwithstanding exposure to the elements and providing a water-proofsurface, such that these products may be employed for roofing, siding,and other similar purposes. More particularly the invention is concernedwith a method for producing the new product set forth and described inmy co-pending application, Serial No. 286,502, filed June 19, 1928, ofwhich the present application is a division.

The product set forth in the co-pending application is to a large extentmade up of a mastic material which is more or less fluent when heatedand hardens on cooling, this mastic giving the element the desired bodyand strength. The material also includes a pair of facing or jacketsheets applied to opposite faces of the mastic mass to give it afinished appearance and also to add to its strength and rigidity.

The method of this invention is one by which the new product may beproduced rapidly,.at low cost, and with a high percentage of the outputof first quality. This method is suitable for production of the newmaterial in various shapes and forms suitable for different uses. As thenew product is of particular utility and affords importantadvantages-when used as a roofing, a form of the method will bedescribed appropriate for the manufacture of roofing material.

Prepared roofing noTv widely used in place of slate, wood shingles andthe like, has numerous advantages and some disadvantages. It is cheaperthan wood shingles, more resistant to fire and of at least equaldurability, but one of the usual components of such roofing is rag feltwhich is relatively expensive. This felt forms the basis of the materialand it is customarily saturated and coated with bituminous substancessuch as asphalt and then given a wear surface of crushed slate, etc. Asthe felt, even in the heaviest and most expensive grades is relativelythin, a roofing element with a felt base is likewise thin and theexposed butt does not cast any considerable shadow so that the appearance of a roof laid with these elements is less attractive than thatof a wood shingle or tile roof. Furthermore, the felt which repre sentsthe greatest item of expense in the manufacture of this roofing isitself the least durable part and in the course of time, the feltdeteriorates and rots due to exposure to the weather, the edges of theelements warp and curl making them unsightly and sometimes causing leaksand in the course of time, the felt disintegrates.

The present invention is accordingly directed to the provisionof amethod by which the novel roofing material of the application aboveidentified may be made at lower cost than prepared roofing employingfelt as a foundation member or base, this method being suitable forproduction of the material in diiferenttshapes and sizes, and inparticular in the form of thick butt shingles.

The mastic which I prefer to use to form the core or base of the newproduct is a mixture in suitable proportions of a bituminous compound,such as asphalt, and granular material or grit, such as crushed rock,crushed slate, sand and other similar substances. In some instances itmaybe desirable to use infusorial earth, ground cork, fibrous asbestosand the like in addition to or in substitution for the granular material.to produce articles of different weights and other characteristics.This mastic material forms a core which is enclosed wholly or in part byfibrous sheets, preferably rag felt, which is not saturated orimpregnated except as an incident to other operations. These sheets forma jacket for the core, adding to its strength and durability, definingits shape and carrying gritty wear material afiixed thereto by asuitable adhesive such as an asphalt coatmg. i

The method of this invention for the production of the new materialinvolves drawing a web of unsaturated felt from a supply, j

and applying to one surface a coating of asphalt or the like. In theordinary roofing process, such felt is saturated with a low melt pointasphalt before any other operation is performed on it, and after this,the felt is cooled and a coating of asphalt of a higher melt point thanthe saturant in which the wear surface is to be embedded is applied. Inthe new process, however, the unsaturated felt receives the coating ofasphalt at once, then the wear surface is applied, and this coatingmaterial is put on in a condition such that it enters into the pores ofthe felt to a substantial distance. The felt used is relatively verythin so that this seeping in of the coating may readily extend partlythrough the felt without difliculty.

After the coating operation, a layer of mastic in more or less fluentcondition 1s applied to the desired thickness on the face of the feltopposite to that coated. This layer of mastic is of substantialthickness but is applied in such condition that the asphaltic componentmay enter into the felt. By properly controlling the application ofcoating and mastic and the fluidity thereof, it is possible to insurethat the coating compound and the plastic ingredient of the mastic,which are the same and preferably asphalt of the same melting point willextend entirely through the felt and unite to produce substantiallycomplete saturation. After the sheet has received its mastic facing, itis cooled so that the mastic receives an initial set. Then a pair ofsuch sheets are placed together with their mastic coatings between, andshaping and cutting operations are performed to unite the sheets into asingle element of the desired form and size. In the finished product,the mastic forms the base, and upon each face is a layer of feltedfibres. Through this layer extends the asphaltic compound in asubstantially continuous mass from the core to the outer layer carryingthe wear surface. The felted sheets forming the jacket are thussufficiently impregnated and saturated and this result is obtainedwithout performing a separate operation for the purpose.

The method of the present invention includes numerous features ofnovelty in addition to these briefly referred to.

For a better understanding of the invention, reference may be had to theaccompanying drawings, in which Figs. 1A and 1B together illustratesomewhat conventionally the layout in side elevation of the apparatusfor producing the new elements;

Fig. 2 is a View in side elevation of modified apparatus for the samepurpose;

Figs. 3 and 4 are views in plan and side elevation, respectively, of oneof the new elements in the form of a shingle;

Figs. 5 and 6 are views of the thinand butt ends, respectively, of thenew element;

Figs. 7 and 8 are plan and side views, respectively, of a modified formof the element;

Fig. 9 is a detail of the apparatus;

Fig. 10 is a view in side elevation of a part of a modified form of theapparatus;

Fig. 11 is a sectional view of a new element;

Fig. 12 is a sectional view illustrating. the manner in which the feltis impregnated;

Fig. 13 is a sectional development view of a part of the shapingapparatus;

Fig. 14 is a sectional view of a part of the apparatus shown in Fig. 13;and

Figs. 15 and 16 are sectional views on the lines 15--15 and 1616,respectively, of Fig. 13.

In these drawings, the element 20 is illustrated in Figs. 36, inclusive,in a form appropriate for use as a shingle. This element is rectangularbut its width may lessen toward the thick or butt end 21. The elementalso tapers in thickness from the rear edge 23 which is the end normallyconcealed toward the butt or exposed end 21. In a modified form shown inFigs. 7 and 8, the element is of substantially uniform width andthickness from the rear end forward to an imaginary transverse linedefining the normal exposure, forward of which the element increases inthickness as indicated at 24, and may decrease in width. The elementsare placed on the roof in the usual courses and each element lies withits side edges at the rear end in contact with the side edges of anadjacent element or slightly spaced therefrom.

Each element comprises a mastic core or base 25 (Figs. 11, 12) which ismade up of a mixture of ingredients previously mentioned. The masticillustrated by way of example preferably includes particles of grit 26,termed a mineral aggregate, fibrous material, and a hinder or vehicle,preferably asphalt of a suitable melting point. This mastic forms thecore or body of the element, and covering each face and also preferablythe end and side edges is a jacket of felted fibres 27 firmly adherentto the core and provided with a coating 28 of asphalt or the like, inwhich are partially submerged or embedded particles 29 constituting awear surface. is an example of the granular material frequently used forsuch a surface, and this may also be used for the aggregate in themastic, though there are other mineral materials equally suitable andsomewhat cheaper such as crushed rock, or sand.

The jacket 27 is preferably made in two pieces, the edges of which maymeet without substantial overlap in the median plane of the element. Bymaking the jacket in two pieces, the edges of which meet withoutsubstantial overlap, it is possible to produce these elements by acontinuous process using certain rotary elements which performoperations without interrupting the progress of the materials, and atthe same time apply the jacket so that it covers both faces and alledges of the core and completely encloses it.

The jacket material employed may be of different materials, such aspaper of relative- Crushed slate ly heavy weight, but I prefer to use alight felt produced 0f rags and similar materials on a paper machine,such felt consisting of felted fibres which provide a porous andabsorbent layer. The felt used however is not comparable in thickness orweight with felts used for standard roofing purposes, but is quite thin,and may vary in weight from 10 to 26 pounds to the unit of 480 squarefeet, while standard roofing felt varies in weight from 20 to 60 poundsfor the same unit. The jacket felt is thus very thin and porous, readilyshaped and easily impregnated.

The new element is made by a process which may be said to involve theapplication of a coating of asphalt and wear material to one face of aweb of this thin felt, the asphalt being applied at a temperature and inamounts such that the asphalt is fluent enough to enter the pores of thefelt to asubstantial depth. After the wear surface has been applied overthis coating, a layer of mastic containing asphalt of the same meltpoint as that used in the coating is applied on the opposite face of thefelt to form a layer of considerable thickness. The mastic is applied ata temperature such that the asphalt therein is relatively fluent andenters the pores of the felt to a depth such that it substantiallycompletes the impregnation thereof, and unites with the asphalt from thecoating so that the felt coated on both sides may be described as madeup of a mastic body with an asphalt coating carrying granular wearmaterial with a thin layer of felted fibres interposed between the massof mastic and the coating layer. Following the application of themastic, the felt is sufiiciently impregnated and saturated and firmlybound thereto.

To complete the element, two webs of felt treated as above described arebrought into juxtaposition with the mastic layers in contact, thencompression is applied to unite the mastic bodies into a single core andto shape the core and jacket, and simultaneously with the shapingoperation, the felt Webs are severed around the outlines of'the formedcore to complete the product. Inthe shaping operation, the jacket sheetsare forcedinto contact at the edges of the shaped core,fand sev: eredalong the line of contact. I This produces a completely jacketed .core,without substantial overlap of the jackets,and permits the shaping andsevering operations to be carried on by rotary molding and cuttingrolls, which produce a completely enclosed core.

This process may be carried on with various forms of apparatus, thatshown in Figs. 1A and 1B being convenient and inexpensive. In thesefigures there are illustrated the two webs of jacket material 30 and 31,mounted on suitable supports so that the webs may be drawn from themwithout difiiculty. Each web 32, 33 passes from its roll through a pairof rolls 34, 35, each roll 34 being provided with a multiplicity of finespikes, while the corresponding roll 35 has a more or less yieldingsurface of rubber, leather or wood. The felt passing between these rollsis punctured at a multiplicity of points and each spike 36 (Fig. 9) isso shaped that as it passes through the felt, it roughens the surfacebeyond which the spike projects. The rolls 34, 35 are. so placed thatthe face of the felt so roughened is the face to which the mastic isapplied. The projecting or roughened parts of the felt then enter themastic layer and increase the strength of the bond between the masticand felt. Also the openings in the felt assist in the saturation of thefelt and permit solid tongues 28 of asphalt to extend directlytherethrough to meet and unite with the asphalt coating layer.

Beyond the perforating devices, the two webs of felt are broughttogether and pass around a guide roll 37 forming part of a coatingmechanism generally designated 38. Standard apparatus 'well known in theart may be used for this purpose. As illustrated diagrammatically, thetwo webs of felt, face to face, are led through a vat 39 of coatingmaterial beneath a guide roll 40, and a coating material applied to theouter faces and edges. From the vat, the webs pass through rolls 41,which remove excess coating material. The coating material which ispreferably asphalt of a melt point sufficient to withstand solar heat ismaintained at a suitable temperature in the vat, so that the asphaltwill flow readily and thus enter the pores of the felt to a substantialdepth.

' From the coater, the webs pass to mechanism generally designated 42,for applying wear material to the coatings. The details of suchmechanism are well known, though these details have here been modifiedand utilized in a way so that surfacing material is applied to oppositefaces of the double web. The two webs pass beneath a hopper 43 beneathwhich is a distributing roll 44, and a layer of the surface grit isspread evenly over the upper surface of the web 33, this grit beingpartially submerged or embedded in the coating by the roll 45 underwhich the webs pass. This roll may be hollow and water-cooled so that itgives the coating an initial set at the same time the grit is embedded.The webs now pass around a guide roll 46, so that the web 32 isuppermost and grit is applied to it by the distributing roll 47receiving grit from the hopper 48. The

webs now pass around roll 49 similar to the roll 45, which embeds thegrit and sets the coating. The webs then pass to the mechanism forapplying the mastic.

This mechanism generally designated 50 includes a pair of rolls 51, 51placed with their surfaces close together, and the webs 32, 33 passupwardly between these rolls and are then separated. A supply of themastic 52 is maintained in the bight of the rolls and kept in place bysuitable end plates, not shown. As the webs separate and pass one aroundeach roll 51, the uncoated faces of the Webs come in contact with therelatively fluent mastic and pick up a layer thereof. Placed to one sideand above each roll 57, is a roll 53, 53 journalled in bearings whichare adjustable with respect to the bearings for the rolls 51 so that thedistance between the surfaces of roll 51 and roll 53, 53' may be varied.Each web is led around the surface of a roll 51, picking up a coating ofmastic,

then between the roll 51 and its associated roll 53 or 53'. The distancebetween the surface of roll 51 and roll 53, for example, determines thethickness of the layer of mastic carried off by the web 32, excessmastic being returned to the supply 52. The web 33 passes over its roll51, then between that roll and roll 53, whereby the thickness of themastic layer is determined, then around that roll to an upper guide roll54.

The various rolls 51, 53, 53' and 54 are hollow and arranged so thatthey may be heated or cooled as may be necessary, and the supply ofmastic 52 is kept at a temperature such that the asphaltic ingredient issufficiently fluent so that it will penetrate the roughened surface ofthe felt and add to the saturation thereof. Also such of these and otherrolls in the apparatus as may be necessary, are driven to cause thefelt-to advance from its supply through the machine. As the coatingasphalt and that in the mastic are preferably the same, they unite inthe felt so that there is a substantially continuous asphaltic massextending through the felted fibres from one face to the other.

From the mastic applying mechanism, the.

two webs of felt are moved to cooling devices, taking the form of rolls55, around which the two webs are led in a tortuous path. These rollsmay be water-cooled so that the coating and the mastic will setpartially. These rolls are used to the number desired or necessary toput the coated webs in suitable condition to be combined into buildingproducts.

The mechanism used for this purpose is similar to that set forth anddescribed in my co-pending application Serial No. 139,612, filed October5, 1926. That mechanism includes a pair of rotary drums 56, having moldcavities 57 in their surfaces. The webs 33, 33 are brought together andpass between the rolls with their mastic layers in contact. The rollsare so shaped that they exert a pressure which consolidates the twomastic layers into a single core of final form, and

the jacket webs conform to the shape of this core. Around their edgesthe mold cavities 57 have sharp edges which pinch the webs and severthem, so that the molding rolls not only form the single elements butcut the webs around the outlines of each element. The drums 56 thusrotate continuously and uniformly and produce finished elements 58without interruption to the movement of the webs. Each element includesa body or core of mastic, which is completely encased in a jacket, andby reason of the choice of a two piece jacket, the edges of which meetin a plane without substantial overlap, the rotary forming operation ispossible, resulting in a high output rate at low cost.

In Fig. 2, there is illustrated a somewhat more compact form of theapparatus. Here the coated webs 32, 33 pass beneath apparatus 59 forapplying grit to the upper web 33, then to apparatus 60 for applyinggrit to the under surface. The grit is embedded in each coating by thepassage of the webs between rolls 51 after which the webs are separatedand receive the coating of mastic from supply 52. The coated webs nowpass directly to the molding drums 56, and the web 32 is guided theretoby roll 53, while web 33 passes around roll 53, guide roll 54 and afloating roll 61 to the drums. The action of the drums may cause masticto collect in their bight at 62 if excess above that required is carriedby the webs. The roll 61 is therefore mounted to float and if masticcollects at 62 in too great amount, it will lift the roll 61 and becarried with roll 53 back to the supply 52.

In Fig. 10, there is illustrated in side elevation a modified form ofthe apparatus, involving the use of two groups of rolls 63 and 64,arranged three high. Each group of rolls is supplied with mastic in anyconvenient manner, for instance, by placing a container for masticadjacent each group, one side of each container being defined by therolls. For this purpose, a pair of downwardly diverging partitions 65may be used as indicated provided with end plates not shown, and holdingquantities of mastic 66 in contact with the surfaces of the two lowerrolls of each group.

The Web 33 is laid between the two upper rolls of the group 63. Themiddle roll 67 of this group is spaced from the lower roll and is drivenat a higher speed than the top and bottom rolls. The roll 67 picks up alayer of mastic from the supply 66 and carries this layer around incontact with the web 33, spreading the mastic on that web under pressurewith a wiping action as the roll revolves. The amount of mastic soapplied will depend upon the spacing of the middle roll from the toproll and bottom roll. The rolls are journaled in bearings capable ofadjustment, so that the thickness of the mastic layer applied to the webcan be varied as desired. The coated web'passes rectly to the formingrolls 56, or it may pass around cooling rolls 55 as desired.

The web 32 passes around a guide roll 69 and then upwardly between themiddle roll and the top roll of the group 64. The rolls of this groupare arranged in the same manner and perform the same function as therolls in the group 63, and, from the top roll of this group, the coatedweb passes either directly to the forming rolls 56, or to cooling rolls55. It will be noted that mastic is applied to the under surface of theweb 33 and to the upper surface of the web 32 by the pressing and wipingor frictioning action of the rolls 67.

It will be seen that the new product can be produced rapidly accordingto the process described, and the apparatus required is of simpleconstruction and low cost. Apparatus such as that illustrated in Figs.1A and 1B will occupy floor space not greatly in excess of feet long andof width not much greater than the units to be produced, whereasstandard roofing equipment of the type now generally used is over 100feet long, and

includes numerous expensive parts. Since the present product utilizesunsaturated felt, and the felt is saturated as an incident to otheroperations, the usual saturating equipment is dispensed with, thusreducing the cost and saving space.

While the new product has been illustrated in the form of a singleshingle, it may be produced in the form of strip shingles by usingmolding drums of appropriate form as illustrated in my co-pendingapplication above referred to. It may also be produced withoutdifficulty in numerous other forms for special purposes.

In Fig. 12, I have illustrated a partof the new element in section andon an enlarged scale. The felt jacket 27 is shown as lying between themastic 25 on one side and the coating layer 28 on the other and due tothe porosity of the felt and its perforation, the

asphalt in mastic and coating has united so that the felt is thoroughlyimpregnated and the core and coating form an integral unit.

This effect is increased b the tongues 28' of asphalt which extendthrough the perforations between the coating and core. Accordingly, thenew element in final form includes a core, a jacket completely encasingthe core, and a water-proof coating with wear material on the jacket andthis product has been produced without starting with a saturated feltand without performing special satura ting steps.

i The present invention affords numerous advantages over the products,processes, and apparatus heretofore used, among which are the following:

By using unsaturated felt the cost of the final product is cut down andthis reduction in cOSt is an important one, since the felt employed isthin and of light weight. The production cost is also reduced since thematerial is converted from unsaturated felt to finished shingles in whatamounts to a single continuous operation, there being no interruption inthe travel of the felt through the apparatus. In the new process, thefelt and mastic are at practically the same temperature when acted on bythe forming and shaping rolls and since the felt is warm it may beappropriately shaped by these rolls without injury to the felt andwithout cracking the sealing coating in which the wear material isembedded. This wear material is also firmly afiixed to the felt since itpasses through two sets of rolls which act upon it and embed it in thesealing coating. The application of the mastic to the felt itself in alayer of regulated thickness insures a uniform supply of mastic to theforming rolls where the core is shaped to final form, and the mastic atthe time itreaches these forming rolls has been subjected to a partialcompression to eliminate voids so that the final pressing operationresults in products of the highest grade. Also, by reason of the use ofunsaturated felt, on one face of which mastic is applied, the binder inthe mastic is forced into the fibres of the felt and unites with thesealing coating, both the mastic and sealing coating being warm at thetime of the final forming operation, and this prevents any separation ordelamination of the felt from the core.

The new product is relatively cheap and it may be made in shingles andbuilding'prodnets of any shape and form. Shingles made by the newprocedure are particularly desirable since they may have the thick butt,so desirable in roofing products, and not obtained with the ordinarycommercial roofing. The thickness of the butt does not increase the costto any substantial extent, since the body of the new shingle is made ofa-relatively inexpensive mastic and the amount of felt or j acketingmaterial used does not vary substantially whether the products are thickor thin. While I have described the method of utilizing the unsaturatedfelt in a product in which the core is completely encased by the jacket,it will be apparent that the same method may also be used to advantagein the production of jacketed elements of other types such as thoseshown in my Patent No. 1,585,692, issued May 25, 1925.

What I claim is:

1. In a process of producing a material suitable for building and otherpurposes, the steps of directly applying to one face only of a web ofunimpregnated felted fibres a coating of a sealing material, cooling theweb and the coating to a preselected temperature adapted to give thecoating an initial set, thereafter applying to the other face of the weba coating of regulated thickness of mastic including particles of solidmaterial and a plastic compound in relativelyfluent condition, and subecting the web so treated to compression to bring about substantialimpregnation thereof by the plastic material and the coating.

2. In a process of producing a material suitable for building and otherpurposes, the steps of applying to one face of a web of felted fibres abituminous sealing coating in relatively fluent condition, applying tothe other face of the web a coating of regulated thickness of a masticincluding bituminous material, and applying pressure with a wipingaction to cause the bituminous material of the coating and the mastic toextend into the felted web a substantial distance and to remove voids inthe mastic, thereafter cooling the web and material carried thereby to atemperature at which the coating and mastic are adapted to yield underpressure without cracking, and finally forming and shaping underpressure the resultant product.

3. In a process of producing a product suitable for building and otherpurposes, the steps of applying to one face of a web of unimpregnatedfelted fibres a coating of bituminous material in relatively fluentcondition, applying to the other'face of the web a layer of regulatedthickness of relatively fluent mastic including bituminous material, andapplying pressure to the opposite faces of the web with a wiping motionto cause the bituminous material of the coating and the mastic to extendinto the web and to intimately bond with the fibers thereof and toproduce thereon a mastic layer of regulated thickness.

4. In a process of producing a material suitable for building and otherpurposes, the steps of applying to one face of a web of unimpregnatedfelted fibres a coating of asphalt in relatively fluent condition,applying to the other face of the web a substantially thicker layer ofregulated thickness of a mastic including solid particles and bituminousmaterial similar to that used for the coating, and wiping the bituminousmaterial of the mastic and the coating into the fibers of the web underpressure thereby substantially impregnating the web therewith anddisplacing any voids among the fibers.

5. A process for making products for building and other purposes, whichcomprises applying a coating of water-resistant sealing material to oneface of each of a pair of webs of felted fibrous material, applying alayer of a mastic to the other face of each web, putting the webstogether with their mastic layers in contact and exerting pressureagainst opposite faces of the webs to unite the mastic layers and moldthe webs and the mastic material between them to predetermined shapes.

6. A process for making products for building and other purposes, whichcomprises applying to one face of each of a pair of webs of feltedfibres a sealing coating resistant to weather, applying to the otherface of each web a layer of mastic material of substantial thickness,placing the webs with their mastic layers in contact and subjecting thewebs to pressure to mold the webs and the mastic material betweenthem topredetermined shapes.

7. A process for making products for building and other purposes, whichcomprises applying to. one face of each of a pair of webs of fibrousmaterial a sealing coating of fusible material in heated condition,applying to the other face of each web a layer of substantial thicknessof mastic material including a fusible binding ingredient in heatedcondition, placing the webs with their mastic layers in contact, andwhile the coating and mastic is still warm, subjecting the webs topressure to mold the webs and the mastic material between them topredetermined shapes. Y

8. -A process for making products for building and other purposes, whichcomprises placing a pair of webs with one face of each in contact,applying a sealing coating to the exposed face of each web, separatingthe webs, applying to the uncoated face of each web a layer of mastic ofsubstantial thickness, placing the webs with their mastic layers incontact, and subjecting the webs and mastic to pressure applied tocompress and form the webs and mastic to predetermined shapes.

9. A process for making products for building and other purposes, whichcomprises applying to one face of each of a pair of webs ofunimpregnated fibrous material a sealing coating in relatively fluentcondition, applying to the other face of each web mastic including arelatively fluent in edient to form a layer of substantial thic ess,placing the webs with their mastic layers in contact and subjecting thewebs and mastic to pressure to force the coating and fluent ingredientof the mastic into the webs to a substantial distance.

10. A process for making products for building and other purposes, whichcomprises applying to one face of each of a pair of webs ofunimpregnated fibrous material a sealing coating in relatively fluentcondition, applying to the other face of each web a mastic whichincludes a relatively fluent ingredient to form a layer of substantialthickness, subjecting each web thus coated to pressure to force thefluent coating and mastic into the web for a substantial distance,placing the webs with their mastic layers in contact, and subjecting thepair of webs with the mastic between to pressure to consolidate themastic layers into a single mass and to form this mass and the webs to apredetermined shape.

11. In a process of producing a material suitable for building and otherpurposes, the steps of perforating a web of fibrous material to roughenone surface thereof, applying to the other surface of the web a coat--ing of material resistant to weather in a rela-v tively fluentcondition, applying to the roughened face of the web with a wipingaction a layer of substantial regulated thickness of a mastic includinga relatively fluent ingredient, and subjecting the coated web topressure to cause the coating and fluent ingredient to pass through theweb and unite therein while controlling the temperature of the web andthe material carried thereby during the application of mastic thereto,

12. In a process of producing a material suitable for building and otherpurposes, the steps of perforating a web of fibrous material to form amultiplicity of openings therethrough and to roughen one surface of theweb, applying a sealing coating to the smooth face of the web, thissealing coating being a fusible bituminous product, applying to theroughened surface of the web a layer of substantial regulated thicknessof a mastic including a fusible bituminous product in.

relatively fluent condition, and subjecting the coated web to pressureto force the coating material and the bituminous ingredient of themastic through the openings in the web.

13. A process for making products for building and other purposes, whichcomprises placing a pair of webs with one face of each in contact andapplying to the exposed face of-each web a sealing coating of bituminousmaterial in relatively fluent condition, separating the webs andapplying to the uncoated face of each a layer of substantial thicknessof a mastic including a bituminous ingredient in relatively fluentcondition, cooling the webs with their coatings to give the sealingcoating and mastic an initial set, thereafter placing the webs withtheir mastic layers in contact, and subjecting the webs and the masticbetween them to pressure to consolidate the mastic layers into a singlemass andto shape the webs and said mass to a predetermined form.

14. A process for making products for building and otherpurposes,whichcomprises applying to one face of each of a pair of webs ofunimpregnated fibrous material a sealing coating in relatively fluentcondition, depositing granular material over the coated surfaces of theweb, and subjecting each web to pressure to cause the granularmaterialto be partially submerged in the coating over which it is applied,applying to the other face of each web a quantity of mastic, including arelatively fluent ingredient to form a layer of substantial regulatedthickness,

placing the webs with their mastic layers in contact, and subjecting theweb with the mastic between them to pressure to force the coating andfluent ingredient of the mastic into the webs.

15. process for making products for building and other purposes, whichcomprises applying sealing material to one face of each of a pair ofwebs of felted fibrous material, applying a layer of mastic in regulatedthickness to the other face of each web, placing the webs with theirmastic layers in contact and exerting pressure against op-' posite facesof the webs to unite the mastic layers. v

16. A process for making products for building, and other purposes,which comprises applying to one face of each of a pair of webs offibrous material a sealing coating of bituminous material in heatedcondition, applyingto the otherface of each Web by means of pressure andwith a wiping motion a layer of substantial thickness of mastic materialincluding a fusible bindingingredient in heated condition, cooling theWebs and materials carried thereby, placing the cooled webs with theirmastic layers in contact and, while the coating and mastic is stillwarm, subjecting the webs to pressure to mold the webs and the masticmaterial between them to a predetermined shape. i

17. A process for making products for building and other purposes, whichcomprises" placing a pair of perforated webs with one face of each incontact, applying a sealing coating to the exposed face of each web,separating the webs, applying to the uncoated face of each web a layerof mastic of substantial thickness by means of a wiping movement appliedunder pressure, thereby forcing the mastic into intimate contact withthe fibers of the Web and through the perforations into intimate contactwith the sealing coating on the opposite side thereof,

placing the thus-treated Webs with their mastic layers in contact, andsubjecting the webs and mastic to pressure suflicient to compress andform the ,webs and mastic to predetermined shape and size.

18. A continuous process for making products for building and otherpurposes, which comprises continuously moving a pair of webs along apredetermined path, and during such movement bringing .the said webstogether with a face of each in contact along a portion of their path oftravel, applying a sealing coating to the exposed face of each of thewebs, thereafter separating the webs, applying to the uncoated face ofeach web a layer of mastic of substantial thickness, placing the webswith their mastic layers in contact and, while the coating and mastic iswarm subjecting the webs and mastic to pressure adapted to compress andform the webs and mastic into a product of predetermined shape.

19. A continuous process for making products for building and otherpurposes, wh1ch comprises continuously moving a number of webs offibrous material along a predetermined path, perforating the respectivewebs during'such movement to form a multlplicity of fine openingstherein and to roughen one surface of each web, subsequently bringingthe said webs together with the respective perforated faces in mutualcontact during a portion of their path of travel, while applying asealing surface coating of a fluent bituminous material to the exposedface of each web, thereafter separating the webs and applying to theuncoated surface of each web a layer of substantial regulated thicknessof a mastic including a fusible bituminous material in relatively fluentcondition, placing the webs with their mastic layers in contact, andsubjecting the webs and mastic to pressure while forming the webs andmastic into a product of preselected shape.

20. A continuous process for making products for building and otherpurposes, which comprises continuously moving a number of webs offibrous material along a predetermined path, perforating the respectivewebs during such movement to form a multiplicity of fine openingstherein and to rough r one surface of each web, subsequently bringingthe said webs together with the respective perforated faces in contactduring a portion of their path of travel, while applying a sealingsurface coating of a fluent bituminous material to the exposed face ofeach web, thereafter separating the webs and applying to the uncoatedsurface of each web a layer of substantial regulated thickness of amastic including a fusible bituminous material in relatively fluentcondition, placing the webs with their mastic layers in contact witheach other, and, while the coating and mastic is warm, subjecting thewebs and mastic to pressure, thereby forcing the coating material andmastic into intimate contact through the openings in the web andcompressing and forming the webs and mastic into a product ofpreselected shape.

21. The process for making products for building and other purposes,which comprises applying to one face of each of a pair of webs ofunimpregnated fibrous material a sealing coating of a relatively fluentwaterproofing material, removing from a source of supply a mastic whichincludes a relatively fluid ingredient and applying a layer of themastic of substantial regulated thickness to the other face of each web,intermittently automatically returning excess mastic to the sald sourceof supply, placing the webs with the r mastic layers together to form acomposite structure, and subjecting the said structure to pressure, toforce the fluent coating and mastic into mutual contact within the web,while consolidating the mastlc layers to form a product of preselectedshape.

22. The process for making products for building and other purposes,WlllCll comprises applying to one face of each of a number of webs ofunimpregnated fibrous material, a sealing coating of fluent bituminousmaterial, applying to each of the said coated faces a surface layer ofsolid wear-resistant material, thereafter applying to the other face ofeach web a mastic which includes a less fluent bituminous ingredientthereby forming a mastic layer of substantial regulated thickness, whilesubjecting each web thus coated to pressure to force the fluent coatingand mastic into mutual contact within the web, placing the webs withtheir mastic layers together, and subjecting the pair of webs and masticto pressure to consolidate the mastic layers into a unitary mass ofpreselected shape.

23. The process for making products for building and other purposes,which comprises applying to one face of each of a number of webs ofunimpregnated fibrous material, a sealing coating of fluent bituminousmaterial, applying to each of the said coated faces a surface layer ofsolid wear-resistant material, Withdrawing a mastic which includes aless fluent bituminous ingredient from a body thereof and frictionallyapplying the said mastic to the other face of each web to form thereon alayer of mastic of regulated thickness while automatically returningexcess mastic to the said body, thereby forcing the fluent coating andmastic into mutual contact within the web, placing the webs with theirmastic layers in contact, and applying pressure to the webs toconsolidate the mastic layers and to form a composite structure ofpreselected shape.

In testimony whereof I affix my signature.

THOMAS ROBINSON.

